Additive Manufacturing

: (Interlaken, Switzerland - Alvin Wei-Cheng Wong)

Harness The Power of 3D Printing

- Overview

Additive manufacturing (AM) is an appropriate name to describe the technologies that build 3D objects by adding layer-upon-layer of material, whether the material is plastic, metal, concrete or one day…..human tissue.

Common to AM technologies is the use of a computer, 3D modeling software (Computer Aided Design or CAD), machine equipment and layering material. Once a CAD sketch is produced, the AM equipment reads in data from the CAD file and lays downs or adds successive layers of liquid, powder, sheet material or other, in a layer-upon-layer fashion to fabricate a 3D object.

The term AM encompasses many technologies including subsets like 3D Printing, Rapid Prototyping (RP), Direct Digital Manufacturing (DDM), layered manufacturing and additive fabrication.

AM technology has the potential to solve the challenges facing companies today by improving the processes required to produce complex products and parts. However, there are still sizable barriers to the practicability of AM, especially at an industrial scale. It will take concerted effort and collaboration from the growing number of additive manufacturing companies to overcome these challenges and realize the potential of AM.

- The Industry of Tomorrow

Additive manufacturing (AM), broadly known as 3D printing, is transforming how products are designed, produced, and serviced. AM enables on-demand production without dedicated equipment or tooling, unlocks digital design tools, and offers breakthrough performance and unparalleled flexibility across industries. But, knowledge remains one of the greatest barriers to AM's wider adoption.

As product development and manufacturing times extend, the pace of innovation is accelerating and market competition is escalating. Manufacturers of everything from passenger cars to smartphones, aircraft and more are striving to bring brand new products to market faster than ever. In addition, companies are trying to respond to growing demand for customizable products, requiring flexibility in manufacturing. Automotive, aerospace, consumer products and other companies must find a way to streamline product development, from design through manufacturing and certification, to overcome these challenges.

AM technology may prove to be the answer. AM technology has the potential to solve the challenges facing companies today by improving the processes required to produce complex products and parts. However, there are still sizable barriers to the practicability of AM, especially at an industrial scale. It will take concerted effort and collaboration from the growing number of additive manufacturing companies to overcome these challenges and realize the potential of AM.

AM is an appropriate name to describe the technologies that build 3D objects by adding layer-upon-layer of material, whether the material is plastic, metal, concrete or one day…..human tissue.

- 3D Printing

The future of prototyping and manufacturing is speeding up and 3D printing is in the front seat. 3D printing has the potential to democratize the production of goods, from food to medical supplies, to great coral reefs. In the future, 3D printing machines could make their way into homes, businesses, disaster sites, and even outer space.

3D printing is a process of making three dimensional solid objects from a digital file. The creation of a 3D printed object is achieved using additive processes. In an additive process an object is created by laying down successive layers of material until the object is created. Each of these layers can be seen as a thinly sliced horizontal cross-section of the eventual object. 3D printing is the opposite of subtractive manufacturing which is cutting out /hollowing out a piece of metal or plastic with for instance a milling machine.

Although the terms "3D printing" and "rapid prototyping" are casually used to discuss additive manufacturing, each process is actually a subset of additive manufacturing. "Additive Manufacturing (AM) is an appropriate name to describe the technologies that build 3D objects by adding layer-upon-layer of material, whether the material is plastic, metal, concrete or one day…..human tissue.

: (MIT photo courtesy of Yu-Chih Ko, MIT)

- Additive Manufacturing (AM)

Additive manufacturing (AM) is the general term for all manufacturing techniques that create physical objects by successively adding material, usually in a layer-by-layer manner. These technologies differ from traditional methods, which either remove material (machining) or somehow shape it (casting and forging). AM is a transformative approach to industrial production that enables the creation of lighter, stronger parts and systems.

It is yet, another technological advancement made possible by the transition from analog to digital processes. In recent decades, communications, imaging, architecture and engineering have all undergone their own digital revolutions. Now, AM can bring digital flexibility and efficiency to manufacturing operations.

AM uses data computer-aided-design (CAD) software or 3D object scanners to direct hardware to deposit material, layer upon layer, in precise geometric shapes. As its name implies, additive manufacturing adds material to create an object. By contrast, when you create an object by traditional means, it is often necessary to remove material through milling, machining, carving, shaping or other means.

- Additive Manufacturing (AM) vs. 3D Printing

Although the terms additive manufacturing (AM) and 3D printing are frequently used interchangeably, the latter is actually just one type of the former. In other words, “additive manufacturing” is a broader term that’s more commonly associated with industrial applications, including the serial production of components.

“3D printing”, on the other hand, has more of a consumer focus. The very nature of the parts made by these two technologies is different: While 3D printing is often used for figurines, decorations, and even small functional parts, additive manufacturing produces molds, components, and end-use products.

- Additive Manufacturing (AM) Technologies

While AM seems new to many, it has actually been around for several decades. In the right applications, additive manufacturing delivers a perfect trifecta of improved performance, complex geometries and simplified fabrication. As a result, opportunities abound for those who actively embrace additive manufacturing.

AM application is limitless. Early use of AM in the form of Rapid Prototyping focused on preproduction visualization models. More recently, AM is being used to fabricate end-use products in aircraft, dental restorations, medical implants, automobiles, and even fashion products.

- AM Applications

While the adding of layer-upon-layer approach is simple, there are many applications of AM technology with degrees of sophistication to meet diverse needs including:

a visualization tool in design
a means to create highly customized products for consumers and professionals alike
as industrial tooling
to produce small lots of production parts
one day….production of human organs

[More to come ...]

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